Replica Props Forum user springsteel came up with an armor design that would work for both Hawkgirl and Wonder Woman. Since Worbla isn’t the cheapest material in the world, it was a way to get the most bang for the buck. She made the Wonder Woman costume first and used both Worbla and Wonderflex for the arm guards, chestplate, and greaves. She coated them with wood glue to prime the pieces (gesso didn’t work for her) and painted them with spray and acrylic paints.
The sword is the especially interesting part. She made the blade from:
…two, extra-long/heavy-duty paint stirrers from Lowes, two normal stirrers, and some wood filler. The hilt is composed of a small length of PVC with leftover Worbla for the cross-guard and Worbla + golf ball for the pommel. I have some faux leather to braid the grip with, diamond-plait style.
People were impressed by her resourcefulness so she documented the process of making the blade from the stirrers:
1. Acquire paint stirrers! For the body of the blade I used two heavy-duty, extra-large stirrers from Lowe’s (about 2 feet long, 1.5 inches wide, and 0.25 inches thick), oriented side-by-side to give the blade a 3-inch width. This will be fortified with two small, typical paint stirrers, one on each side of the blade.
2. I used wood glue to fix the two LARGE stirrers together, then “paper mache’d” them by running a strip of newspaper, dampened with woodglue, down the length of the blade, over the “seam.”
3. The new large blade was carved to shape and beveled with a utility knife (the large stirrers were wonderfully soft). Then, each small stirrer was also carved to match the shape of the blade. This was glued on top of the larger blade, one on each side, and clamped into place.
4. Once the glue dried, I shaped everything up with a little jitterbug sander, and carved a channel down the center of the small stirrer portion of the blade for detail. I then ran a bead of wood putty down the channel and pulled the excess out with my finger (to give it a smooth, indented look). Wood putty was also used around the edges of the small stirrer and smoothed out to the edges of the main blade – to create a long bevel from the thick center to thin edge.
5. The whole thing was sanded smooth and covered in ~4 layers of Titebond woodglue. I sprayed the blade down with some off-brand silver paint, added details with black and silver acrylics, and covered the whole thing in 2-3 layers of Modge Podge for protection.
More information and pictures at The RPF.